Emergency Test Control Panel Device, System and Method

ABSTRACT

Embodiments disclosed herein include a test control panel device, system, computer program product, and method for receiving a test input signal; reading a duration of the test input signal; verifying that the signal duration is a valid duration to initiate the test; initiating the test by sending a start test signal to a valve controller device; receiving signals from the valve controller device; indicating that the test control panel device has received a valve controller device signal from the valve controller device; wherein the valve controller device signal is a test acknowledgement signal.

FIELD OF TECHNICAL ART

This disclosure relates to devices, systems, and methods for testingprocess control systems and, in particular, to devices, systems, andmethods for testing an emergency shutdown system in a process plant, orfor testing components of such a system in a process plant.

BACKGROUND

To maintain the safety of a process plant, a process plant may includean integrated or separately-controlled emergency shutdown system. Anemergency shutdown system is intended to help contain a hazardouscondition that may occur in or around a process plant. For example, someprocess plant systems, such as oil refineries or natural gas processingplants may require a quick shutdown if a fire were to break out in oraround the process plant. An emergency shut down system may shut downthe operation of the process plant by cutting off further supply ofmaterials to the process plant. The system may take over the operationof the process plant when it detects errors or dangerous conditionsexisting in an area of the process plant and may shut down a main linevalve that controls the supply of input materials to the process plant.The emergency shutdown system may employ a valve controller that shuts asupply valve of the process plant to prevent further flow of inputmaterial through the valve, which may prevent further flow of thematerial to the remainder of the process plant.

Some emergency shutdown systems may deteriorate over time and, inparticular, may deteriorate to a state where the emergency shutdownsystem fails to operate properly. For example, in a pneumatic actuatorused to close a highly-pressurized valve, dirt or other foreignmaterials may accumulate in the actuator or in the valve such that theactuator or the valve may fail or become stuck. Of course, if theactuator or valve that fails or becomes stuck (e.g., due to corrosion,accumulation foreign materials, etc.) the actuator or valve may notoperate properly in response to a control signal.

In view of the potential for the emergency shutdown systems orcomponents to fail at a crucial time if they are not properly tested andmaintained, it is often desirable to test systems and components (e.g.,valves, controllers, actuators) making up an emergency shutdown system,to ensure that the components will operate properly in an emergency. Onemethod of testing the operation and/or response of a device to a shutdown command is to issue a shut down command and determine whether thedevice responds to the command. In the case of an emergency shut downvalve, this may include issuing a command to fully close the valve anddetermining whether the valve closes as expected. However, a test thatinvolves completely closing a valve may be costly and may cause a largedisturbance in the operation of the process plant.

An alternative to the complete shutdown test is to attach a bypass valveas a safety valve so that the safety valve can be fully shut down bywhat is referred to as a “full stroke” test without shutting down theprocess plant. However, there may be economic and operational problemsassociated with the bypass valve technique. Therefore, conventionaldiagnostics techniques have been developed that close a valve to betested to a certain percentage toward a full closure of the valve. Thesetests are referred to as partial stroke (closure) tests.

However, problems may exist with conventional partial stroke tests. Inparticular, after the initiation of a conventional partial stroke test,it may take some time before a valve controller physically moves thevalve off of the valve's travel stop. Some time may be required totransfer a user-initiated partial stroke test signal into a visibleindication that the test is in progress. Because conventional emergencyshutdown systems may not provide an immediate indication to a user thatthe user has initiated a partial stroke test, a user may not think thetest has been initiated. Therefore, the user may try to initiate thetest again by hitting a start test button for a second time in an effortto start the test while not having yet received an indication that thepartial stroke test actually has been initiated. An additional problemmay occur with conventional test systems if the user repeatedly hits thestart test button. Because the user may not have an indication that thetest system initiated his test, the user may hit a start test buttonagain, but in actuality, the user may be turning on and off the testwithout the user being aware of his unintended actions.

SUMMARY

In accordance with an aspect of the invention, a test control paneldevice includes a test input device configured to receive a test inputsignal, a timer for reading a duration of the test input signal, averification device configured to verify that the signal duration is avalid duration to initiate the test, a transmitter device configured toinitiate the test by sending a start test signal to a valve controllerdevice, a receiver device configured to receive a signal from the valvecontroller device, and an output indicator device configured to indicatethat the test control panel device has received a valve controllerdevice signal from the valve controller device, wherein the valvecontroller device signal is a test acknowledgement signal.

In accordance with an aspect of the invention, a testing system includesa test input device configured to receive a test input signal, a timerfor reading a duration of the test input signal, a verification deviceconfigured to verify that the signal duration is a valid duration toinitiate the test, a transmitter device configured to initiate the testby sending a start test signal to a valve controller device, a receiverdevice configured to receive signals from the valve controller device,and an output indicator device configured to indicate that the testcontrol panel device has received a valve controller device signal fromthe valve controller device, wherein the valve controller device signalis a test acknowledgement signal.

In accordance with an aspect of the invention, a computer programproduct having a computer readable medium including programmedinstructions for testing a system, wherein the instructions performreceiving a test input signal, reading a duration of the test inputsignal, verifying that the signal duration is a valid duration toinitiate the test, initiating the test by sending a start test signal toa valve controller device, receiving signals from the valve controllerdevice, and indicating that the test control panel device has received avalve controller device signal from the valve controller device, whereinthe valve controller device signal is a test acknowledgement signal.

In accordance with an aspect of the invention, a test control paneldevice includes a test input device configured to receive a test inputsignal, a timer for reading a duration of the test input signal, averification device configured to verify that the signal duration is avalid duration to initiate the test, a transmitter device configured toinitiate the test by sending a start test signal to a valve controllerdevice, a receiver device configured to receive a signal from the valvecontroller device, and an output indicator device configured to indicatethat the test control panel device has received a valve controllerdevice signal from the valve controller device, wherein the valvecontroller device signal is a test acknowledgement signal, wherein thetest is a partial stroke test, wherein the valve controller devicesignal is any one of the group consisting of: a position sensor signal,a pressure sensor signal, or a current sensor signal or any one of thegroup consisting of: a loop current signal, a travel set point signal, atravel signal, or a DVC startup signal.

DRAWINGS

FIG. 1 is a general diagram of a process plant having an emergencyshutdown system and illustrating an embodiment of a test control panelsystem assembled in accordance with teachings of the present invention,wherein some of the components of the test control panel system may beshared with an emergency shutdown system and/or with a process plantsystem.

FIG. 2 is an embodiment of a test control panel system that may includea test control panel device along with a digital valve controller and/orother shared components which may also be part of the emergency shutdownsystem or the process plant system of FIG. 1.

FIG. 3A is an embodiment of a test control panel device that maycommunicate with a digital valve controller.

FIG. 3B is another embodiment of a test control panel device that maycommunicate with a digital valve controller.

FIG. 4 is a flow diagram of an embodiment of the logic of a test controlpanel device or system.

FIG. 5 is a table of exemplary signaling combinations including someselected signaling which may be produced by the test control paneldevice.

FIG. 6 is another table of exemplary signaling combinations includingsome selected signaling which may be produced by the test control paneldevice.

DESCRIPTION

FIG. 1 is a general diagram of a process plant 100 which may be, forexample, a chemical, petroleum, or other types of process plant, and mayhave an emergency shutdown system 101 and a test control panel system200. The test control panel system 200 may share some components (e.g.,shared components 110) with the emergency shutdown system 101 and/or theprocess plant 100. The example process plant of FIG. 1 includes one ormore workstations 17, one or more I/O devices 18, one or more processors11 disposed in one or more controllers 19, and a plurality of fielddevices 12-15, each of which field devices may be, for example, a valve,a valve positioner/actuator, a switch, transmitter (e.g., for sensingand transmitting temperature, pressure, fluid level, flow rate, etc.),etc., and each of which field devices performs a process function suchas opening or closing a valve, measuring a process parameter, etc. Theworkstations 17, the I/O devices 18, the controllers 19, and the fielddevices 12-15 cooperate to form a process control system 102 thatcontrols the process during normal operation.

Additionally, the system 100 may include one or more field devices, suchas an emergency shutdown valve 16, that are part of systems in additionto the control system 102. The emergency shutdown valve 16, for example,may also be part of the emergency shutdown system 101 and/or the testcontrol panel system 200 (i.e., the emergency shutdown valve 16 may beone of the shared components 110). The test control panel system 200includes, in addition to the emergency shutdown valve 16, a test controlpanel device 310 coupled to the emergency shutdown valve 16.Communication buses 20, which may include analog buses, digital buses,and/or combined analog and digital buses, may communicatively couple thefield devices 12-15 and the emergency shutdown valve 16 to the processcontrollers 19.

During normal operation, the control system 102 operates the emergencyshutdown valve 16. However, in the event of an emergency, the emergencyshutdown system 101 operates to command the emergency shutdown valve 16close (or open), thereby protecting the system and/or personnel in theprocess plant 100. Of course, the emergency shutdown system 101 may, insome embodiments, be built into the control system 102 such that thesame control system 102 that operates the emergency shutdown valve 16during normal operation also controls the emergency shutdown valve 16during an emergent situation.

Generally, the emergency shutdown system 101 operates to minimizedangerous conditions that may occur in the process plant 100. Forexample, during operation, the emergency shutdown system 101 may detecta hazardous condition, and then send a signal, such as a full-scale(e.g., 20 mA in a 4-20 mA scale) or a zero-scale (e.g., 0 mA or 4 mA ina 4-20 mA scale) current, to a digital valve controller 206 to powerdown the digital valve controller 206. When the digital valve controller206 is powered down the emergency control valve 16 may move to itssafety condition.

As generally known by those of ordinary skill in the art, certainbenefits may be achieved by testing whether components of a processplant or components of an emergency shutdown system will operateproperly before a real emergency occurs. For example, testing of theemergency control valve 16 may be beneficial. Testing of othercomponents may also be beneficial and these other components and theircommunications may also be included in embodiments of the test controlpanel system 200.

Some of the field devices 12-15 and/or the emergency shutdown valve 16may be smart field devices, such as field devices conforming to thewell-known Fieldbus protocols, (e.g., the FOUNDATION™ Fieldbusprotocol), may also perform control calculations, alarming functions,and other control functions commonly implemented within the processcontrollers 19. The process controllers 19, which may be located withinthe plant environment, may receive signals indicative of processmeasurements made by the field devices 12-15 and the emergency shutdownvalve 16, and/or may receive signals indicative of other informationpertaining to the field devices 12-15 and the emergency shutdown valve16. The process controllers 19 may execute (e.g., on the processors 11)a controller application that runs, for example, different controlmodules which make process control decisions, generate control signalsbased on the received information and coordinate with the controlmodules or blocks being executed in the field devices, such as HART andFieldbus field devices. The control modules in the process controller 19may send the control signals over the buses 20 to the field devices12-15 and/or the emergency shutdown valve 16 to thereby control theoperation of the process.

A network connection 21 may facilitate sharing of information from thefield devices 12-15, the emergency shutdown system 101, the test controlpanel system 200, and the controllers 19 with one or more other hardwareand/or software devices, such as the workstations 17, other personalcomputers (not shown), one or more data historians (not shown), one ormore report generators (not shown), one or more centralized databases(not shown), etc. The workstations 17 (and other hardware connected viathe network connection 21) typically reside in control rooms or otherlocations away from the harsher environment of the process plant 100,but are nevertheless generally considered part of the process plant 100.The network connection 21 may also facilitate sharing of information(e.g., process control data from the field devices 12-15, the emergencyshutdown valve 16, the controllers 19, etc.) with other hardware and/orsoftware devices and systems, such as the test control panel system 200or the test control panel device 310 in the test control panel system200.

These hardware and/or software devices and, in particular, theworkstations 17, execute applications that may, for example, enable anoperator to perform functions with respect to the process, such aschanging settings of the process control routine, modifying theoperation of the control modules within the controllers 19, the fielddevices 12-15, and/or the emergency shutdown valve 16, viewing thecurrent state of the process, viewing alarms generated (e.g., by thefield devices 12-15, the emergency shutdown valve 16, the controllers19, etc.), simulating the operation of the process for the purpose oftraining personnel, testing the process control software (or runningother tests), keeping and updating a configuration database, etc.

One example of software that may run on the workstations 17 and/or thecontrollers 19 is the DeltaV™ control system, sold by Emerson ProcessManagement, and includes multiple applications stored within andexecuted by different devices located at diverse places within theprocess plant 100 (e.g., within the controllers 19, the I/O devices 18,the workstations 17, etc.). A configuration application, which residesin one or more of the operator workstations 17, enables users to createor change process control modules and download these process controlmodules via the network connection 21 to the process controllers 19.Typically, these control modules are made up of communicativelyinterconnected function blocks, which function blocks are objects in anobject-oriented programming protocol and perform functions within thecontrol scheme based on inputs to the controllers 19 from the fielddevices 12-15 (and the emergency shutdown valve 16). The control modulesmay also provide outputs to other function blocks within the controlscheme. A configuration application or a test application may also allowa designer to create or change operator interfaces or human-machineinterfaces (HMIs) which a viewing application uses to display data to anoperator and to enable the operator to change settings, such as setpoints, or test data, within the process control routine or to runtests.

Each of the process controllers 19 and, in some cases, the field devices12-15 and/or the emergency shutdown valve 16, may store and execute anapplication that runs the respective modules to implement actual processcontrol functionality or test functionality. One or more workstations17, may run a viewing application, may receive data from the controllerapplication or from a test application via the network connection 21,may display the received data to process control system designers,operators, or users using the user interfaces, and may provide any of anumber of different views, such as an operator's view, an engineer'sview, a technician's view, etc.

The process plant 100 illustrated in FIG. 1 employs the emergencyshutdown system 101 to take over control of the components of theprocess plant 100 if the emergency shutdown system 101 detects ahazardous condition, such as a fire, a high pressure indication, etc.The emergency shutdown system 101 may, for example, send a signal to theemergency shutdown valve 16 to perform an action (such as closing oropening the valve) to achieve a safety condition. Of course, while theembodiments described herein contemplate a scenario where the safetycondition of the emergency shutdown valve 16 is a closed position, thesafety condition of the emergency shutdown valve 16 may be an openposition, a closed position, or a partially open/closed position,depending on the particular application and/or process.

FIG. 2 illustrates an embodiment of the test control panel system 200.The test control panel system 200 may include the test control paneldevice 310, one or more communication links 211, 212, a test inputsignal 214, an output indicator 216, and various components 210, includethe emergency shutdown valve 16, a digital valve controller 206, asolenoid valve 202, and a valve actuator 204. Some of all of thecomponents 210 may be shared components 110 that also operate under theprocess control system 102. The test control panel system 200 may alsoinclude various signals, such as a feedback signal 213, between one ormore of the components 210.

The test control panel system 200 may test one or more components toverify that the device is operative to perform its safety function inthe event of an emergency. For example, the test control panel system200 may test the emergency control valve 16 by running a partial stroketest to verify that the emergency control valve 16 operates properly(e.g., closes, opens, moves smoothly and/or at the correct speed, etc.).Of course, other components may be included in, or tested by, theemergency shutdown system 200, including any of the components describedin U.S. Pat. Nos. 6,862,547 and 6,186,167, each of which is herebyincorporated by reference in its entirety.

Some conventional test systems exhibit characteristics that make theiruse problematic. In particular, in some partial stroke test systems asignificant time delay may exist between the time when a user initiatesa partial stroke test and the time at which the valve controllerphysically moves the emergency control valve off of its travel stop.Even in systems in which an indicator informs the user that the systemhas initiated a partial stroke test, the indicator often operatesaccording a switch located on the travel stop. Thus, in such systems,the same significant time delay may exist.

Significant time delays between the initiation of a test and the visibleindication that the test is running may cause a user to believe thatinitiation of the test was unsuccessful. As a result, the user mayre-try to initiate the test (e.g., by pressing a “start test” buttonagain) in an effort to start the test. In some instances, the repeatedpressing of a start button creates a problem in that it instructs thesystem to cancel the test which, unbeknownst to the user, the useralready initiated successfully.

The presently-described test control panel system 200 provides asolution to this problem by including a test response signal whichindicates to the user that the user has successfully initiated the test(e.g., the partial stroke test). For example, a test control panelsystem 200 may automatically run a partial stroke test based upon therequirements of the particular process plant 100 or embodiments of thetest control panel system 200, which may also allow for a manualinitiation of a test. For example, the embodiment of the test controlpanel system 200 may produce a test response signal to respond to a testbeing initiated by a user.

Alternative tests that can be run with the test control panel device 310of test control panel system 200 include a test which may be run to testany particular component of an emergency shutdown system 101, such as atest that checks if a shaft is broken, a test that checks for actuatordamage, a valve is stuck, etc. or a test that checks for a plurality ofcomponents operating together properly, etc.

As illustrated in FIG. 2, the test control panel system 200 includes thetest control panel device 310 and the digital valve controller 206. Thetest control panel device 310 and the digital valve controller 206 maycommunicate with each other via communication links 211, 212, which maybe wired or wireless links, or may be one link or multiple links.Additionally, the test control panel device 310 and the digital valvecontroller 206 may communicate with any component used in the particulartest run by the test control panel system 200 (e.g., the solenoid valve202, the actuator 204, etc.). As illustrated, the test control paneldevice 310 may communicate to and from the digital valve controller 206to send and receive diagnostic test information regarding the testinitiated by the test control panel device 310.

The user may initiate a partial stroke test (or other test) bymechanically moving a switch, such as a button, or the control system102 or the emergency shutdown system 101 may be programmed toautomatically initiate a partial stroke test (or other test) at aperiodic time interval or based on some other criterion. FIG. 2illustrates an embodiment in which a “start” button 215 on the testcontrol panel device 310 operates to send a test input signal to thedigital valve controller 206, which test input signal indicates that thedigital valve controller device 206 should perform a partial stroketest. The test control panel device 310 may also include a test inputsignal 214 for indicating the test control panel device 310 isoutputting the test input signal to the digital valve controller 206.

During the partial stroke test, the digital valve controller 206controls the functionality of any of the components 210 involved in thetest (e.g., the emergency shutdown valve 16, the solenoid valve 202, andthe actuator 204) by sending a test signal to the device. After thedigital valve controller 206 receives an input and determined to be atest signal instructing the controller to execute a partial stroke test(e.g., a signal from the test control panel device 310), the digitalvalve controller 206 may proceed with the partial stroke test byretrieving a configurable script or routine. During operation of thepartial stroke test, the digital valve controller 206 may continue tomonitor other inputs, such as an abort signal used to indicate a realemergency and override any current testing. However, in the absence ofan abort signal, the digital valve controller 206 may send a signal tothe solenoid valve 202, which solenoid valve 202 may adjust thepneumatic pressure in the actuator 204 by directing the pressure to thevalve actuator 204 or to an exhaust valve (not shown). Accordingly, theactuator 204 moves the emergency shutdown valve 16.

For example, the embodiment of FIG. 2 illustrates the digital valvecontroller 206 configured to send a pneumatic signal to a solenoid valve202. The solenoid valve 202 may include a solenoid control which mayreceive direct current (DC) power and electrical control signals fromother components of the power plant or emergency shutdown system 101.The controller of the solenoid valve 202 is configured to send a signalto control the pressure output of the solenoid valve. The solenoid valve202 may send a pneumatic signal to the actuator 204, which causes theactuator 204 to send an electronic signal to move a plug of theemergency control valve 16 as part of the partial stroke test. Forexample, the actuator may ramp the valve 16 from the normal 100 percentopen position to a partially closed position and then back again to itsnormal state.

The feedback signal 213 may originate at any of the components 210involved in the partial stroke test. For example, any of the solenoidvalve 202, the actuator 204, or the emergency shutdown valve 16 (orother sensors disposed among or associated with the components 210) mayprovide the feedback signal 213 to the digital valve controller 206,which may send a feedback signal (e.g., via communication link 212) tothe test control panel device 310. Alternatively, the digital valvecontroller 206 may, upon receiving the test signal and initiating thepartial stroke test, transmit a feedback signal directly to the testcontrol panel device 310 via, for instance, the communication link 212.The test control panel device 310 may indicate to the user that the userhas successfully initiated the partial stroke test by illuminating theindicator 216.

A feedback signal may be obtained at any point toward the completion ofthe signaling to initiate the partial stroke test of the emergencycontrol valve 16. The feedback signal 213 may be obtained from any ofthe devices involved in the partial stroke test. For example, anelectronic feedback signal 213 may be a travel feedback signal obtainedfrom the actuator 204. Other examples of where a feedback signal may beobtained include the solenoid valve 202, or the valve 16, etc.

For example, the test control panel devices 310A, 310B include threelight output indicators 216A-C as the embodiment of an overall outputindicator device 32. For example, one fast blinking green light outputindicator 216A may indicate that the test control panel device 310 areceived an acknowledgement response from the digital valve controller206 in response to a start partial stroke test signal that was sent fromthe test control panel device 310 a.

FIG. 3A and FIG. 3B illustrate in additional detail two embodiments310A, 310B, of the test control panel device 310 and the respectivesystems 200A, 200B in which the embodiments 310A, 310B exist. Asillustrated in FIG. 3A, the test control panel device 310A includes aninput device 31, an output indicator device 32 having one or moreindicators 216, a timer or counter 33, a verification device 34, atransmitter/receiver device 35, memory 36, a processor 37, a test inputsignal 214, a button 216, an analog/digital converter 38 and adigital/analog converter 39. Of course, the functionality and devices ofany features of the test control panel device 310 may be implemented inhardware, firmware, or software, or any combination of the three.Additionally, any of the components of the test control panel device 310may be distributed to another component of the test control panel system200, such as a digital valve controller 206.

Operation of one embodiment of the test control panel device 310 isdescribed with reference to FIG. 3A. To initiate the partial stroketest, the user causes the generation of a test indication signal (e.g.,by depressing the button 215 on the input device 31). The timer 33receive the test indication signal and may determine (e.g., by timing orcounting) the duration of the test initiation signal. The timer 33 maycommunicate the determined duration to the verification device 34 toverify that the signal is a valid duration. Alternatively, the timer 33may communicate the determined duration directly to the processor 37and/or the memory 36, and the processor 37 may verify that the signalduration is a valid duration. In any event, after the input signal hasbeen determined to have a valid duration, the TX/RX device 35 maycommunicate the start test signal to the digital valve controller 206via the communication links 211A, 212A.

FIG. 3B illustrates an alternative embodiment of a test control panelsystem 200B which includes a test control panel device 310B coupled tothe digital valve controller 206 via communication links 211B, 212B. Atest control panel device 310B may include input and output components,such as the input device 31 and the output device 32. The test inputsignal 214 may be an indicator illuminated by a DC signal that isswitched on by the push button 215 on the input device 31. Outputindicators 216 may be one or more light emitting diodes (LEDs), such asa green LED 216A, a yellow LED 216B, a red LED 216C, etc. One or more ofthe LEDs 216 may indicate (e.g., by staying on, blinking in a pattern,etc.) that the test control panel device 310A has transmitted the starttest signal and/or that the digital valve controller 206 has receivedthe start test signal. Further exemplary indications implementingindicators 216A-C and their signals are described with reference to FIG.5 and FIG. 6. The remaining components of the test control panel device,illustrated in FIG. 3A as included in the test control panel device 310A(e.g., the D/A converter 39, the processor 37, the verification device34, the timer/counter 33, the A/D converter 38, the memory 36, theTX/PRESCRIPTION device 35, etc.) are, in the embodiment illustrated inFIG. 3B, included in the digital valve controller 206. Of course, theembodiments of the test control panel systems 200A, 200B may include ananalog and/or a digital module that supplies signals to any testedcomponent without requiring communications via the digital valvecontroller 206.

The operation of the test control panel device 310B is explained belowwith reference to FIG. 3B. The test control panel device 310B mayreceive the test input signal 214 from the button 215 on the inputdevice 31. This causes the test control panel device 310B to send astart test signal, such as the start partial stroke test signal, to thedigital valve controller 206 via the communication link 211B. After thedigital valve controller 206 has monitored for input and received thepartial stroke test input signal and, in some embodiments, determinedand verified the length of the signal, the digital valve controller 206sends a pressure signal to the solenoid valve 202. After receiving thepressure signal from the solenoid valve 202, the actuator 204 sends asignal to move the emergency shutdown valve 16 by ramping the emergencyshutdown valve 16 from its normal state to a test position and then backagain to its normal state.

The digital valve controller 206 may send back a test response signal tothe test control panel device 310B via the communication link 212B. Amodule (not shown) of the digital valve controller 206 may interpret thereceived test response signal and determine how to indicate theinterpreted data to the user via the output indicators 216. Variousmethods of indicating the interpreted data to the user via theindicators 216 are described with reference to FIG. 5 and FIG. 6.

FIG. 4 illustrates an embodiment of a method 400 of initiating a testusing the test control panel system 200 and indicating a result of aninitiated test. The example method 400 may be implemented using theembodiments of system 200 or the test control panel device 310 or anyequivalents thereof. The method 400 commences as a user (or the processcontrol system 102) initiates a partial stroke test (block 41) by, forexample, sending a start test signal (e.g., by depressing the button 215on the input device 31). The test control panel system 200 (e.g., at theinput device 31) receives the start test signal (block 42) and evaluates(e.g. by the timer 33) the duration of the signal (block 43).Subsequently, the verification device may verify that the determinedduration is within a valid range (block 44), such as between 3 and 10seconds, or any other specified duration. If the duration is valid, thedigital test control panel system 200 may send a signal that wouldfacilitate the test (block 45). Following transmission of the signal tofacilitate the test, the test control panel system 200 may receive(e.g., from the digital valve controller 206) a test response signal(block 46). Based upon the received test response signal the testcontrol panel system 200 may indicate (e.g., by output indicator devices216 the received test response signal (block 47), for example, as shownin any of the exemplary embodiments illustrated in FIG. 5 and FIG. 6.

FIG. 5 and FIG. 6 illustrate exemplary embodiments of available testresponse signals that may be sent by a component used during testing,such as by the digital valve controller 206, to indicate a state of atest, such as a partial stroke test. For example, the index columnidentifies the number of an exemplary embodiment of response signal andoutput indication combinations. An embodiment of how these indicatorsmay be used in the field is indicated by the selected combinations. Forexample a test response signal may be any one or more of the groupconsisting of: a position sensor signal, a pressure sensor signal, or acurrent sensor signal or any one or more of the group consisting of: aloop current signal, a travel set point signal, a travel signal, or aDVC startup signal. Any of these signals or a combination of suchsignals may be used to indicate a test state.

The test state may be indicated by the output indicator 216. Forexample, output indicator 216 may be any one or more of the groupconsisting of: a solid green light, a fast green blinking light, a slowgreen blinking light, a solid red light, a fast red blinking light, aslow red blinking light, solid yellow light, a fast yellow blinkinglight, or a slow yellow blinking light. In one instance, the outputindicator 216 as listed in index 4 of FIG. 5 illustrates a trippedtravel set point signal as indicated by a combination of a solid yellowlight and a fast blinking green light. The blinking or flashing mayinclude different rates or patterns to distinguish between signalsreceived to show any state of any tested component of the emergencyshutdown system 101 or the process plant 100.

The output indicators 216 may indicate to the user various statusinformation determined by interpreting the received test responsesignal. For example, the information may be information indicatingwhether a start partial stroke test signal was successfully sent outfrom the test control panel device 310. The information may beinformation indicating that the digital valve controller 206 hasreceived the appropriate response signal from the actuator 204. Theinformation may be an indication that the actuator has begun moving thevalve 16.

In another embodiment, the output indicator 216 may be used to indicatewhether other devices that are further down the line in facilitatingcommunication to the emergency control valve 16, such as a solenoidvalve 202 (FIG. 2), an actuator 204 (FIG. 2), or an emergency controlvalve 16, alone or in combination, have successfully received theirrespective communication in relation to the user's test initiationinput.

The embodiments of the test control panel device 310 and/or the testcontrol panel system 200 described herein may be used for testing (e.g.,with a partial stroke test) emergency shutdown systems including anemergency shutdown valve, and for providing an indication of the statusor result of the test that was administered to an emergency shutdownvalve. As described above, embodiments of the test control panel device310 and/or the test control panel system 200 described herein may beused for testing any component of an emergency shutdown system 101 or aprocess plant 100.

Embodiments of the disclosure are not limited to components that areshared and may otherwise include components that make up a redundantemergency shutdown system 101 which includes additional components forshutdown purposes. Embodiments of the disclosure may also includecomponents that are integrated and therefore shared with the processplant 100 rather than being under control of the separate emergencyshutdown system 101.

The test control panel system 200 and, in particular, the test controlpanel device 310, may test any of the components of the process plant100, including components of the emergency shutdown system 101. Theembodiments of test control panel system 200 may include the componentsof the test control panel device 310, which may be spread acrossdifferent locations, if beneficial. Examples of the components that maybe tested, such as components of the emergency shutdown system 101,include a separate emergency shutdown controller, an impedence booster,a digital communicator, a digital valve controller, a solenoid valve, avalve actuator, feedback signals, or the emergency control valve itself16.

Some of the disclosed embodiments provide an improvement over thefeedback of conventional emergency shutdown systems by including moreimmediate, more precise, and/or more intuitive feedback indication ofthe status of the testing being done to a component, such as anemergency shutdown valve 16 which is taking part in a partial stroketest. The benefits of providing improved feedback to a user when runningtests improves the efficiency of maintenance operations of the processplant. For example, improved feedback regarding the testing of anemergency system reduces the likelihood of incorrect test interpretationby a test operator. Further, better feedback reduces the down time andproblems that result from an incorrectly interpreted test. Theseproblems may be dangerous when for example a partial stroke test resultis misinterpreted as indicating a pass, when it actually failed.

Alternative embodiments of the test control panel device 310 or system200 may include explosion proof or intrinsic safety implementations, ortest override modules which are used to override a test if an emergencyshutdown command is initiated by process plant 100 or emergency shutdownsystem 101. For example an explosion proof terminal cover may be usedwith any component of the test control panel device 310, test controlpanel system 200.

Some embodiments were made in light of the above noted problems with theconventional art. In accordance with some of the embodiments of thepresent invention, it is possible to have an improved indication andstatus of what is occurring with a valve or other components of anemergency shutdown system or process plant after a test, such as apartial stroke test, has been initiated.

1. A test control panel device comprising: a test input deviceconfigured to receive a test input signal; a timer for reading aduration of the test input signal; a verification device configured toverify that the signal duration is a valid duration to initiate thetest; a transmitter device configured to initiate the test by sending astart test signal to a valve controller device; a receiver deviceconfigured to receive a signal from the valve controller device; anoutput indicator device configured to indicate that the test controlpanel device has received a valve controller device signal from thevalve controller device; wherein the valve controller device signal is atest acknowledgement signal.
 2. The device according to claim 1, whereinthe duration is 3 to 10 seconds and the test is a partial stroke test.3. The device according to claim 1, wherein the valve controller devicesignal is any one of the group consisting of: a position sensor signal,a pressure sensor signal, or a current sensor signal or any one of thegroup consisting of: a loop current signal, a travel set point signal, atravel signal, or a DVC startup signal.
 4. The device according to claim1, wherein the output indicator device is configured to produce anaudible or visible indicator.
 5. The device according to claim 1,wherein the output indicator device is configured to cause a lightemitter diode (LED) to flash in a pattern.
 6. The device according toclaim 1, wherein the output indicator device is configured to cause alight emitter diode to flash repeatedly to indicate that the valvecontroller device signal was an acknowledgement signal.
 7. The deviceaccording to claim 1, wherein the output indicator device is configuredto cause an output display dependent upon the type of the valvecontroller device signal that was received by the test control paneldevice.
 8. The device according to claim 7, wherein the output displayis a light emitting diode.
 9. The device according to claim 1, furthercomprising any one or a combination of the following: a green LED, ayellow LED, or a red LED.
 10. The device according to claim 1, whereinany one of or both of the transmitter or receiver device is a wirelessdevice.
 11. A testing system comprising: a test input device configuredto receive a test input signal; a timer for reading a duration of thetest input signal; a verification device configured to verify that thesignal duration is a valid duration to initiate the test; a transmitterdevice configured to initiate the test by sending a start test signal toa valve controller device; a receiver device configured to receivesignals from the valve controller device; an output indicator deviceconfigured to indicate that the test control panel device has received avalve controller device signal from the valve controller device; whereinthe valve controller device signal is a test acknowledgement signal. 12.The system according to claim 1, wherein the duration is 3 to 10 secondsand the test is a partial stroke test.
 13. The system according to claim1, wherein the valve controller device signal is any one of the groupconsisting of: a position sensor signal, a pressure sensor signal, or acurrent sensor signal or any one of the group consisting of: a loopcurrent signal, a travel set point signal, a travel signal, or a DVCstartup signal.
 14. The system according to claim 1, wherein the outputindicator device is configured to produce an audible or visibleindicator.
 15. The system according to claim 1, wherein the outputindicator device is configured to cause a light emitter diode (LED) toflash in a pattern.
 16. The system according to claim 1, wherein theoutput indicator device is configured to cause a light emitter diode toflash repeatedly to indicate that the valve controller device signal wasan acknowledgement signal.
 17. The system according to claim 1, whereinthe output indicator device is configured to cause an output displaydependent upon the type of the valve controller device signal that wasreceived by the test control panel device.
 18. The system according toclaim 7, wherein the output display is a light emitting diode.
 19. Thesystem according to claim 1, further comprising any one or a combinationof the following: a green LED, a yellow LED, or a red LED.
 20. Thesystem according to claim 1, wherein any one of or both of thetransmitter or receiver device is a wireless device.
 21. A computerprogram product having a computer readable medium including programmedinstructions for testing a system, wherein the instructions perform:receiving a test input signal; reading a duration of the test inputsignal; verifying that the signal duration is a valid duration toinitiate the test; initiating the test by sending a start test signal toa valve controller device; receiving signals from the valve controllerdevice; indicating that the test control panel device has received avalve controller device signal from the valve controller device; whereinthe valve controller device signal is a test acknowledgement signal. 22.The computer program product according to claim 1, wherein the durationis 3 to 310 seconds and the test is a test.
 23. The computer programproduct according to claim 1, wherein the valve controller device signalis any one of the group consisting of: a position sensor signal, apressure sensor signal, or a current sensor signal or any one of thegroup consisting of: a loop current signal, a travel set point signal, atravel signal, or a DVC startup signal.
 24. The computer program productaccording to claim 1, wherein the indicating that the test control paneldevice has received a valve controller device signal includes producingan audible or visible indicator.
 25. The computer program productaccording to claim 1, wherein the indicating that the test control paneldevice has received a valve controller device signal includes causing alight emitter diode (LED) to flash in a pattern.
 26. The computerprogram product according to claim 1, wherein the indicating that thetest control panel device has received a valve controller device signalincludes causing a light emitter diode to flash repeatedly to indicatethat the valve controller device signal was an acknowledgement signal.27. The computer program product according to claim 1, wherein theindicating that the test control panel device has received a valvecontroller device signal includes causing an output display dependentupon the type of the valve controller device signal that was received.28. The computer program product according to claim 7, wherein theindicating that the test control panel device has received a valvecontroller device signal includes using a light emitting diode.
 29. Thecomputer program product according to claim 1, further comprising anyone or a combination of the following: lighting a green LED, lighting ayellow LED, or lighting a red LED.
 30. The computer program productaccording to claim 1, wherein any one of or both of the sending orreceiving includes using a wireless procedure.
 31. A test control paneldevice comprising: a test input device configured to receive a testinput signal; a timer for reading a duration of the test input signal; averification device configured to verify that the signal duration is avalid duration to initiate the test; a transmitter device configured toinitiate the test by sending a start test signal to a valve controllerdevice; a receiver device configured to receive a signal from the valvecontroller device; and an output indicator device configured to indicatethat the test control panel device has received a valve controllerdevice signal from the valve controller device; wherein the valvecontroller device signal is a test acknowledgement signal; wherein thetest is a partial stroke test; wherein the valve controller devicesignal is any one of the group consisting of: a position sensor signal,a pressure sensor signal, or a current sensor signal or any one of thegroup consisting of: a loop current signal, a travel set point signal, atravel signal, or a DVC startup signal.